DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. Breather cap 2. Air breather pipe 3. Vacuum hose 4. Vacuum hose >>d<< 5. 4LLC operation detection switch 6. Gasket 7. Steel ball >>d<< 8. 2WD detection switch 9. Gasket 10. Steel ball >>d<< 11. Center differential lock detection switch 12. Gasket 13. Steel ball >>d<< 14. 4H detection switch 15. Gasket 16. Steel ball >>d<< 17. 2WD/4WD detection switch 18. Gasket 19. Steel ball 20. Wiring harness bracket 21. Wiring harness bracket >>c<< 22. Control housing 23. Spring pin 24. Change shifter >>b<< 25. Transfer 26. Connector bracket

Disassembly steps >>a<< 27. Back-up lamp switch <V5M31-E-KDL, ME, MEL, SF, SFL> or 5th and reverse rail switch <V5M31-E-XCL> >>a<< 28. 3rd and 4th rail switch <V5M31-E-XCL> >>a<< 29. 1st and 2nd rail switch <V5M31-E-XCL> 30. Gasket 31. Steel ball 32. Gasket 33. Steel ball 34. 4WD detection switch <V5M31-E-XCL> 35. Gasket >>Z<< 36. Resistance spring plug 37. Resistance spring 38. Steel ball >>Y<< 39. Upper cover 40. Seal bolt >>X<< 41. Neutral return spring >>X<< 42. Neutral return plunger A >>X<< 43. Neutral return plunger B >>W<< 44. Nut >>W<< 45. Special bolt 46. Stopper bracket <<A>> 47. Spring pin 48. Control shaft 49. Control finger >>V<< 50. Transfer case adapter 51. Air breather bracket 52. Connector bracket <V5M31-E-XCL> 53 Connector bracket <V5M31-E-KDL, ME, MEL> 54 Connector bracket <V5M31-E-KDL, ME, MEL>

Disassembly steps <<B>> >>U<< 55. Lock nut <<B>> >>U<< 56. Lock nut <<C>> >>T<< 57. Ball bearing >>S<< 58. Counter reverse gear 59. Thrust washer >>R<< 60. Reverse idler gear 61. Needle bearing <<D>> >>Q<< 62. Ball bearing >>P<< 63. Reverse gear 64. Needle bearing 65. 5th speed shift lever >>O<< 66. Spring pin 67. Poppet plug >>N<< 68. Poppet spring 69. Steel ball 70. Reverse shift fork >>M<< 71. Reverse synchronizer sleeve 72. Reverse shift rail 73. Snap ring 74. 5th speed shift fork >>L<< 75. 5th speed synchronizer sleeve 76. 5th speed shift rail <<E>> >>K<< 77. Reverse gear bearing sleeve 78. Synchronizer spring 79. Synchronizer ring >>J<< 80. Reverse brake gear >>I<< 81. 5th speed synchronizer hub 82. Synchronizer ring 83. Synchronizer spring <<F>> >>H<< 84. Counter 5th speed gear <<F>> 85. Reverse idler gear shaft 86. Needle bearing

Disassembly steps >>G<< 87. Clutch housing 88. Inspection hole cover >>F<< 89. Oil seal >>E<< 90. Spacer <<G>> 91. Snap ring >>D<< 92. Transmission case

Disassembly steps >>C<< 93. Spring pin >>C<< 94. Spring pin 95. 3rd-4th speed shift rail 96. 3rd-4th speed shift fork 97. 1st-2nd speed shift rail 98. 1st-2nd speed shift fork 99. Interlock plunger 100. Interlock plunger >>B<< 101. Seal bolt 102. Rear bearing retainer 103. Snap ring 104. Snap ring <<H>> >>A<< 105. Intermediate plate 106. Main drive pinion 107. Needle bearing 108. Synchronizer ring 109. Synchronizer spring 110. Main shaft 111. Counter shaft cluster gear

With the control finger at the neutral position, remove the spring pin.

1.Slide the shift forks as illustrated to put the two gears into engagement.

2.Using the special tool Lock nut wrench (46) (MD998835) to remove the main shaft lock nut.

3.Using the special tool Lock nut wrench (41) (MD998809) to remove the counter shaft cluster gear lock nut.

using the special tool Bearing and gear puller (MD998348) to remove the ball bearing from counter shaft cluster gear.

using the special tool Bearing and gear puller (MD998348) to remove the ball bearing from main shaft.

1.Attach the special tool Bearing puller (MD998020) to the reverse brake gear. 2.Screw the center bolt of special tool, and pull out the reverse gear bearing sleeve, synchronizer spring and ring together.

Lift the counter 5th speed gear to the slit in the reverse idler gear shaft and remove them altogether.

While pushing the main shaft and counter shaft cluster gear against the intermediate plate, remove the snap rings from the rear bearing retainer mounting surface.

caution Removing the intermediate plate will set free the mainshaft, countershaft cluster gear and main drive pinion at the same time. Lightly tapping the intermediate plate with a plastic hammer or similar tool, remove the intermediate plate from the main drive pinion, main shaft, and counter shaft cluster gear.

1.Install the main drive pinion to the transmission case.

2.Put solders (1.0 mm diameter, about 10 mm long) on the ball bearing at the positions shown in the illustration. 3.Install the clutch housing and tighten the bolts to the specified torque of 35 ± 6 N·m. 4.Remove the clutch housing and remove the solder. 5.If the solders have not crushed, use thicker solders (1.6 mm diameter, about 10 mm long) and repeat steps 2 to 4.

6.Measure the thickness of the crushed solder with a micrometer and select spacers that will provide the standard value. Spacer thickness: (T1 - 0) to (T1 - 0.1) T1: The crushed solder thickness mm Standard value: 0 - 0.1 mm

1.Install the main drive pinion to the transmission case. 2.Installs the adjusting spacer having the minimum thickness.

3.Put plastigage (about 10 mm long) on the ball bearing at the positions shown in the illustration. 4.Install the clutch housing and tighten the bolts to the specified torque of 35 ± 6 N·m. 5.Remove the clutch housing and take out the crushed plastigage.

6.If the plastigages have not crushed, replace the spacer with a thicker one and repeat steps 3 to 5. 7.Measure the width of the crushed Plastigage at its widest part using a scale printed on the plastigage package. Spacer thickness: (T2 + T3 - 0) to (T2 + T3 - 0.1) Spacer thickness: (T2 + T3 - 0) to (T2 + T3 - 0.1) T3: The spacer thickness used for measurement mm Standard value: 0 - 0.1 mm

1.Install the main shaft and counter shaft cluster gear to the transmission case.

2.Using a plastic hammer, install the intermediate plate. note Push the intermediate plate until the snap ring grooves for the main shaft and counter shaft cluster gear bearings come out the rear bearing retainer mounting surface. 3.Install the snap ring.

Apply the specified sealant to the threads. Specified sealant: 3M STUD Locking No. 4170 or equivalent note The new bolt does not require sealant application as it is precoated with sealant.

Press in the spring pin so that its slit is parallel with the shift rail.

Apply the specified sealant to the transmission case before installation. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

Install the previously selected spacer. (Refer to ADJUSTMENT BEFORE REASSEMBLY .)

1.Using special tool Oil seal installer (MD998304) install the oil seal into the clutch housing. 2.Apply specified grease to the lip of the oil seal. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

caution Be careful not to damage the oil seal by the spline of the main drive pinion. Apply the specified sealant to the transmission case before installation. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

Before reassembly, make sure that the counter 5th speed gear faces the correct direction.

Before reassembly, make sure that the 5th speed synchronizer hub faces the correct direction.

Use special tools to install the reverse brake gear. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (42) (MD998820)

Use special tools to install the reverse gear bearing sleeve. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (40) (MD998819)

Before reassembly, make sure that the sleeve faces the correct direction.

Before reassembly, make sure that the sleeve faces the correct direction.

Install the poppet spring with the small end directed to the steel ball.

Press in the spring pin so that its slit is parallel with the shift rail.

Install the reverse gear while aligning the deep grooves in the synchronizer hub section with the projection on the sleeve inner periphery.

Use special tools to install the ball bearing to the mainshaft. Installer cap (MD998812) Installer-100 (MD998813) Installer adapter (40) (MD998819)

Before reassembly, make sure that the sleeve faces the correct direction.

Before reassembly, make sure that the sleeve faces the correct direction.

Use special tools to install the ball bearing to the countershaft cluster gear. Installer cap (MD998812) Installer adapter (34) (MD998817)

1.Slide the synchronizer sleeves as illustrated to put the two gears into engagement.

2.Using the special tool Lock nut wrench (46) (MD998835) to tighten the main shaft lock nut to the specified torque of 255 ± 10 N·m.

3.Using the special tool Lock nut wrench (41) (MD998809) to tighten the counter shaft lock nut to the specified torque of 255 ± 10 N·m.

4.Stake the two lock nuts firmly using a punch or like.

Apply specified sealant to the transmission case mating surface of the transfer case adapter as illustrated. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

1.Apply the specified sealant to the bolt as shown. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

2.Apply the specified sealant to the nut threads. Specified sealant 3M AAD Part No. 2353 or equivalent

Coat the entire surface of the neutral return plunger with grease. Then, install the neutral return plunger to the upper cover and attach the spring. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent

Apply a bead of specified sealant to the upper cover as illustrated. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

Apply the specified sealant to the resistance spring plug as illustrated. Specified sealant: 3M AAD Part No. 8660 or equivalent

Install the switches, ensuring that each is installed correctly as identified by the identification tape. Mounting Position Rail switch Identification tape color A 1st and 2nd Red B 3rd and 4th Blue C 5th and reverse White

1.Apply specified sealant to the transfer case adapter mating surface of the transfer. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

2.Apply grease to the leading end of the transfer input gear as illustrated. Specified lubricant: Mitsubishi Part No. 0101011 or equivalent 3.Assemble the transfer and transmission with care not to damage the control shaft oil seal. At this time, mount the change shifter to the control shaft.

Apply specified sealant to the illustrated position of the control housing. Specified sealant: Mitsubishi Part No. MD997740 or equivalent

Install the switches as illustrated. Mounting Position Switch Name Tube color Connector color A 2WD/4WD detection switch Blue Black B 4LLC operation detection switch Black Brown C 2WD detection switch Black Black D 4H detection switch Green White E Center differential lock detection switch Blue Brown